A high-strength and ultra-fast curing cement blanket

Abstract

The present invention relates to the technical field of cement blankets, and more specifically, to a high-strength, ultrafast-curing cement blanket comprising a surface layer matrix, a middle layer matrix, and a bottom layer matrix arranged sequentially from top to bottom. The middle layer matrix comprises a skeleton and a curable mixture, the skeleton being connected to the surface layer matrix on its upper side and to the bottom layer matrix on its lower side. The curable mixture comprises cement and reinforcing fibers. This solves the problem in the prior art that pure cement within cement blankets is prone to drying, cracking, and agglomerating, thereby reducing the performance of the blanket. By employing magnesium phosphate cement, the cement blanket can be rapidly hardened.

Description

Technical Field

[0001] The invention relates to the technical field of cement blankets, in particular to a high-strength and ultra-fast curing cement blanket. Background Art

[0002] With the rapid development of society and the economy, the construction and civil engineering industries have experienced rapid growth, placing increasing demands on construction quality. Construction has also expanded to locations with harsh conditions, such as ditches, slope protection, and mining areas in high-risk and complex terrain. The use of existing building composite materials, such as concrete and rubble stone, requires temporary mixing. Manual mixing results in uneven mixing and generates large amounts of dust, increasing workers' workload and polluting the environment. To address these issues, cement blankets are currently commonly used as construction materials. Cement blankets, scientifically known as concrete canvas, are soft, cement-impregnated cloth that undergoes a hydration reaction upon contact with water, hardening into a thin, durable, waterproof, and fireproof concrete layer.

[0003] A cement blanket typically includes a mesh structure consisting of a top layer, a bottom layer, and a connecting layer. The cavity between the bottom layer and the top layer is filled with cement-based dry powder. After the cement blanket is constructed, it solidifies when exposed to water, forming a concrete-like structure. During the use of the cement blanket, the cement blanket is first laid in the location where it is needed. Then, the cement in the cement blanket is solidified when exposed to water, forming a concrete-like structure. However, most cement blankets in the prior art use pure cement inside, without the many aggregates found in concrete. This causes the pure cement to easily dry out and crack during the curing process. Due to the limitations of the upper and lower layers of the cement blanket, it is generally difficult to add conventional aggregates to the middle of the cement blanket. As a result, the cement in the cement blanket can only rely on the upper and lower layers of the cement blanket and the connecting layer in the middle as attachment points during the curing process, which plays a role in preventing cracking. However, the interior of the cement blanket will still form some dry and cracked blocks due to the solidification of the pure cement, which reduces the performance of the entire cement blanket. Summary of the Invention

[0004] The object of the present invention is to provide a high-strength and ultra-fast curing cement blanket, so as to solve the problem in the prior art that pure cement inside the cement blanket is prone to drying, cracking, and agglomeration, thereby reducing the performance of the cement blanket.

[0005] In order to solve the above technical problems, the present invention adopts the following technical solutions:

[0006] A high-strength, ultra-fast curing cement blanket comprises a surface layer matrix, a middle layer matrix and a bottom layer matrix arranged in sequence from top to bottom. The middle layer matrix comprises a skeleton and a curable mixture. The upper side of the skeleton is connected to the surface layer matrix, and the lower side is connected to the bottom layer matrix. The curable mixture is filled between the surface layer matrix and the bottom layer matrix; the curable mixture comprises cement and reinforcing fibers.

[0007] A further technical solution is that the skeleton includes column lines, the surface layer matrix includes an upper woven mesh and an anti-slip belt, the bottom layer matrix includes a mesh layer and a lower packaging layer, the column lines are reciprocatingly woven and connected with the upper woven mesh and the mesh layer, and several columns are formed between the upper woven mesh and the mesh layer to leave a gap between the upper woven mesh and the mesh layer; the anti-slip belt is arranged on the upper side of the upper woven mesh; the lower packaging layer is connected to the lower side of the mesh layer by bonding.

[0008] A further technical solution is that the material of the upper woven mesh is one of carbon fiber, basalt fiber, ultra-high molecular weight polyethylene, steel fiber, steel wire, polyester, and nylon; the material of the column line is one of carbon fiber, basalt fiber, ultra-high molecular weight polyethylene, steel fiber, steel wire, polyester, and nylon; the material of the lower encapsulation layer is one of carbon fiber, basalt fiber, ultra-high molecular weight polyethylene, steel fiber, and steel wire.

[0009] A further technical solution is that the reinforcing fibers are steel fibers, and both ends of the steel fibers are bent to form end hooks.

[0010] A further technical solution is that the cement is magnesium phosphate cement.

[0011] A further technical solution is that a reinforcing rib is further provided on the lower side of the lower woven mesh, and the reinforcing rib is provided along the width direction of the lower woven mesh; a plurality of reinforcing ribs are provided, and the spacing between two adjacent reinforcing ribs is set to 1-2m;

[0012] A further technical solution is that the anti-slip belt is a diamond abrasive anti-slip belt.

[0013] A further technical solution is that it also includes an upper connecting bar and a lower connecting bar, which are respectively arranged on opposite sides of the edge of the cement blanket; the lower side of the upper connecting bar is provided with an upper curing groove with an opening facing downward, and the upper side of the lower connecting bar is provided with a lower curing groove with an opening facing upward, and both the upper curing groove and the lower curing groove are filled with a curable mixture.

[0014] A further technical solution is that the upper curing tank is provided with a first water-soluble film at the slot opening for sealing the upper curing tank, and the lower curing tank is provided with a second water-soluble film at the slot opening for sealing the lower curing tank.

[0015] A further technical solution is that a first honeycomb plate is provided in the upper curing tank for dividing the upper curing tank into a plurality of honeycomb holes; and a second honeycomb plate is provided in the lower curing tank for dividing the lower curing tank into a plurality of honeycomb holes.

[0016] Compared with the prior art, the present invention has the following advantages: 1. By setting up a skeleton, the surface layer matrix and the bottom layer matrix can be well supported, so that there is enough space between the surface layer matrix and the bottom layer matrix to accommodate the curable mixture; 2. By filling reinforcing fibers in cement, the reinforcing fibers can be used as cement aggregate to enhance the compressive strength and flexural strength of the cement. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 This is an overall schematic diagram of a high-strength and ultra-fast curing cement blanket according to the present invention.

[0018] Figure 2 This is a schematic cross-sectional view of a high-strength and ultra-fast curing cement blanket according to the present invention.

[0019] Figure 3 The figure is a schematic diagram showing the connection between the upper connecting strip and the lower connecting strip of a high-strength and ultra-fast curing cement blanket according to the present invention.

[0020] Figure 4 This is a schematic diagram of the second honeycomb panel of a high-strength and ultra-fast curing cement blanket of the present invention.

[0021] Icon: 1-upper woven mesh, 2-lower encapsulation layer, 3-column line, 4-cement, 5-reinforced fiber, 7-column, 8-mesh layer, 10-end hook, 12-anti-slip tape, 13-reinforcement rib, 14-upper connecting strip, 15-lower connecting strip, 16-upper curing groove, 17-lower curing groove, 18-first water-soluble film, 19-second water-soluble film, 20-second honeycomb panel. DETAILED DESCRIPTION

[0022] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0023] Figures 1 to 4 Shown is an embodiment of the present invention.

[0024] Example 1:

[0025] like Figure 1 、 2As shown, a high-strength, ultra-fast curing cement blanket comprises a surface layer matrix, a middle layer matrix, and a bottom layer matrix, arranged sequentially from top to bottom. The middle layer matrix includes a skeleton and a curable mixture. The skeleton is connected to the surface layer matrix on the top and to the bottom layer matrix on the bottom. The curable mixture is filled between the surface layer matrix and the bottom layer matrix. The curable mixture comprises cement 4 and reinforcing fibers 5. The skeleton effectively supports the surface layer matrix and the bottom layer matrix, thereby ensuring sufficient space between the surface layer matrix and the bottom layer matrix to accommodate the curable mixture. By filling the cement 4 with reinforcing fibers 5, the reinforcing fibers 5 serve as cement aggregate, thereby enhancing the compressive and flexural strengths of the cement 4.

[0026] The skeleton includes column wires 3, the surface layer substrate includes an upper woven mesh 1 and an anti-slip tape 12, the bottom layer substrate includes a mesh layer 8 and a lower encapsulation layer 2, the column wires 3 are woven back and forth with the upper woven mesh 1 and the mesh layer 8, and a number of columns 7 are formed between the upper woven mesh 1 and the mesh layer 8 to leave a gap between the upper woven mesh 1 and the mesh layer 8; the anti-slip tape 12 is arranged on the upper side of the upper woven mesh 1; and the lower encapsulation layer 2 is connected to the lower side of the mesh layer by bonding. Using 3D weaving technology, the upper woven mesh 1, the mesh layer 8, and the column wires 3 are woven together. During weaving, the combined portion of the upper woven mesh 1 and the column wires 3 forms a dense moisture-absorbing layer that can penetrate water during installation, allowing the water to wet the cement 3 and solidify it. A layer of anti-slip layer can also be installed between the upper woven mesh 1 and the anti-slip tape 12 to improve the overall anti-slip properties of the cement blanket.

[0027] The material of the upper woven mesh 1 is one of carbon fiber, basalt fiber, ultra-high molecular weight polyethylene, steel fiber, steel wire, polyester, and nylon; the material of the column line 3 is one of carbon fiber, basalt fiber, ultra-high molecular weight polyethylene, steel fiber, steel wire, polyester, and nylon; the material of the lower packaging layer 2 is one of carbon fiber, basalt fiber, ultra-high molecular weight polyethylene, steel fiber, and steel wire.

[0028] The reinforcing fibers 5 are steel fibers, each bent at both ends to form hooks 10. This creates a good interfacial effect between the steel fibers and the magnesium phosphate cement matrix, resulting in excellent bonding. The steel fibers selected are hook-shaped micro-steel fibers with a length of 3-6 mm and a diameter of 0.23 mm. These fibers can be matched to the mesh openings on the three-dimensional woven framework. The bending-to-compression ratio reflects the toughness and deformation resistance of the composite. A higher toughness coefficient indicates better deformation resistance, and vice versa. Experimental measurements show that the optimal dosage is 0.8%-2%, as shown in Table 1.

[0029] In actual use, the end hooks 10 of the steel fibers improve cement adhesion and allow two steel fibers to connect with each other, enhancing the overall crack resistance of the cement blanket. Furthermore, the end hooks 10 not only connect the steel fibers to each other but also to the upper woven mesh 1 or the lower encapsulation layer 2, further stabilizing the connection between the curable mixture and the framework. This effectively prevents cracking of the cement 4.

[0030] Cement 4 is magnesium phosphate cement. Ultra-fast curing cement: Phosphate cement is preferably magnesium phosphate cement, sulfoaluminate cement, etc. It can solidify within 30-45 minutes, reaching a compressive strength of ≥20MPa and a flexural strength of ≥5MPa. The corrosion of steel seriously affects the bearing capacity and service life of reinforced concrete structures and steel structures themselves. Magnesium phosphate is a compound of the same type with similar properties to aluminum phosphate and zinc phosphate, and has anti-steel corrosion properties. Magnesium phosphate cement has fireproof and anti-corrosion properties for steel, and is resistant to sulfate erosion and chloride ion erosion.

[0031] The lower encapsulation layer 2 is also equipped with reinforcing ribs 13, extending along its width. Several ribs 13 are provided, with the spacing between adjacent ribs 13 set at 1-2 meters. The anti-slip strips 12 are made of corundum, spaced every 10 meters. The reinforcement ribs 13 enhance the overall strength of the cement blanket, especially when installed horizontally. For a 1-meter-wide cement blanket, the ribs 13 have a height of 0-5 cm.

[0032] Cement uses magnesium phosphate cement as filler because it has great advantages in fast hardening as a fast-hardening and early-strengthening cementitious material. It can achieve:

[0033] The initial setting time of the composite material is ≤30min, and the final setting time is ≤45min.

[0034] After 60 minutes of hardening, the compressive strength reaches or exceeds 20MPa, and the flexural strength reaches or exceeds 5MPa.

[0035] After 90 minutes of hardening, the compressive strength reaches or exceeds 40MPa, and the flexural strength reaches or exceeds 7.5MPa.

[0036] This feature ensures the rapid construction and early strength requirements of the cement blanket, making rapid construction and emergency repairs possible.

[0037] Magnesium phosphate cement is a new inorganic cementitious material composed of dead-burned magnesium oxide, phosphate, and a retarder. It has unique properties and advantages in certain applications. Here are some of the properties and advantages of magnesium phosphate cement:

[0038] Rapid Setting: Magnesium phosphate cement sets and hardens quickly after reacting with water, making it useful in applications where a quick cure is required.

[0039] High early strength: Compared with traditional cement, magnesium phosphate cement has higher early strength and is suitable for projects that need to gain strength quickly.

[0040] Resistance to chemical erosion: Magnesium phosphate cement has good resistance to some chemical erosion and corrosion and can be used in some special environments.

[0041] High temperature resistance: Due to the compounds produced during its hardening process, magnesium phosphate cement still has good stability in high temperature environment.

[0042] In terms of technology, after filling the cement, the vibration screening and compaction process is used to ensure that the cement blanket is densely and evenly filled, eliminate gaps and uneven areas, improve the overall uniformity and durability, and increase the service life and stability of the cement blanket.

[0043] Through these core technological advantages, our cement blanket not only meets the basic functional requirements of traditional cement products, but also achieves characteristics such as rapid hardening, high strength, high durability and diverse functions through structural optimization and material selection, making it possible for its wide use in different application scenarios.

[0044] The oscillatory compaction process applies vibration energy to force cement into the concrete matrix, reducing voids in the cement. Repeated oscillations and compaction improve the density, stability, and mechanical properties of the cement blanket. This process effectively increases the density of the cement blanket, minimizes voids, and avoids post-curing voids, ensuring the structural safety and durability during use.

[0045] Oscillation and compaction process

[0046] Preparation: Prepare cement, cement blanket, and vibration and compaction equipment, ensuring that the equipment is in good condition and meets the operating requirements. The cement blanket at this time does not have the lower encapsulation layer 2.

[0047] Loading materials: The cement blanket is conveyed into the oscillating compactor and the cement is loaded into the feed port of the oscillating compactor by means of a conveyor belt, bucket elevator, etc. The bottom of the cement blanket is facing upwards so that the cement can pass through the mesh layer and enter between the upper woven mesh 1 of the cement blanket and the mesh layer.

[0048] Oscillation compaction treatment: Start the oscillation compaction equipment and pressurize and vibrate the cement blanket so that the cement is densely filled in the cement blanket and fills the entire fiber layer.

[0049] Repeat the shaking and compacting process: If a more uniform distribution and higher compaction are required, the shaking and compacting process can be repeated several times.

[0050] Cleaning and maintenance: After the treatment is completed, clean the vibration and compaction equipment in time to ensure the normal operation and long-term use of the equipment.

[0051] Oscillating compaction equipment. The main principle of oscillating compaction equipment is to improve the density, strength, and stability of materials by applying vibration and compaction forces. Oscillating compaction equipment consists of a vibrating mechanism and a pressure-applying mechanism. The vibration frequency, amplitude, and applied pressure can be controlled to meet different vibratory compaction requirements.

[0052] After the oscillation compaction is completed, the lower packaging layer 2 is installed on the cement blanket by bonding.

[0053] Example 2:

[0054] On the basis of Example 1, Figure 3 、 4 As shown, the present invention also includes upper and lower connecting bars 14, 15, which are respectively arranged on opposite sides of the edge of the cement blanket. The lower side of the upper connecting bar 14 is provided with an upper curing groove 16 with a downward opening, and the upper side of the lower connecting bar 15 is provided with a lower curing groove 17 with an upward opening. Both the upper and lower curing grooves 16, 17 are filled with a curable mixture. Conventional cement blankets are simply connected by overlapping two pieces. While this method is simple, the thickness of the overlapping portion exceeds the thickness of the cement blanket itself, which is not aesthetically pleasing and may cause unnecessary trouble in areas where thickness requirements are required. By providing the upper and lower connecting bars 14, 15, the upper and lower connecting bars 14, 15 of two adjacent cement blankets can be aligned and installed when multiple cement blankets are installed. This allows the curable mixture in the upper and lower curing grooves 16, 17 to mix and cure, thereby stably connecting the upper and lower connecting bars 14, 15. This ensures the installation of two adjacent cement blankets. At the same time, it can prevent the overlap thickness from exceeding the cement blanket itself. The edges of the cement blanket will be sealed with some water-permeable materials. The upper connecting strips 14 and the lower connecting strips 15 are fixed to the edge of the cement blanket with these edge-sealing materials. On the one hand, it can allow the moisture inside the cement blanket to flow into the upper connecting strips 14 and the lower connecting strips 15, and on the other hand, it can solidify the edge with the help of the cement slurry that penetrates into the edge sealing.

[0055] The upper curing tank 16 is provided with a first water-soluble film 18 at the notch position for sealing the notch of the upper curing tank 16, and the lower curing tank 17 is provided with a second water-soluble film 19 at the notch position for sealing the notch of the lower curing tank 17. The first water-soluble film 18 and the second water-soluble film 19 can prevent the curable mixture in the upper curing tank 16 and the lower curing tank 17 from leaking out before the cement blanket is installed. When the cement blanket is in use, the first water-soluble film 18 and the second water-soluble film 19 are dissolved with water, so that the curable mixture in the upper curing tank 16 and the lower curing tank 17 are mixed together for curing. When the cement blanket is not in use, protective strips can be installed on the surfaces of the first water-soluble film 18 and the second water-soluble film 19 to prevent scratches on the first water-soluble film 18 and the second water-soluble film 19. The protective strips can be removed when in use. The protective strips can be fixed to the edge of the upper curing tank 16 or the lower curing tank 17 by gluing. The first water-soluble film 18 and the second water-soluble film 19 are made of cold water-soluble materials. The specific dissolution time is selected to be faster than the cement setting time to avoid the situation where the cement begins to set before the water-soluble film dissolves. There are many water-soluble films available on the market, and the one that meets the effect is sufficient.

[0056] A first honeycomb panel is provided within the upper curing tank 16 to divide the upper curing tank 16 into a plurality of honeycomb holes. A second honeycomb panel 20 is provided within the lower curing tank 17 to divide the lower curing tank 17 into a plurality of honeycomb holes. The provision of the first and second honeycomb panels 20 allows for uniform distribution of the curable mixture within the upper and lower curing tanks 16, 17, preventing accumulation that would result in uneven strength at the connection point when the upper connecting strip 14 and the lower connecting strip 15 are connected. Furthermore, the curable mixture can be prevented from accumulating and squeezing the first or second water-soluble film 18, 19, causing damage. The first and second honeycomb panels 20 can be made of a water-permeable material, such as fiber cloth or perforated steel mesh, to allow for water to flow between the honeycomb holes on the first and second honeycomb panels 20.

[0057] Although the present invention has been described herein with reference to a number of illustrative embodiments thereof, it will be understood that numerous other modifications and implementations may be devised by those skilled in the art that fall within the scope and spirit of the principles disclosed herein. More specifically, within the scope of the present disclosure, the drawings, and the claims, numerous variations and modifications may be made to the components and / or layout of the subject combination arrangement. In addition to variations and modifications to the components and / or layout, other uses will also be apparent to those skilled in the art.

Claims

1. A high-strength and ultra-fast curing cement blanket, comprising a surface layer substrate, a middle layer substrate and a bottom layer substrate arranged in sequence from top to bottom, characterized in that: The middle layer matrix comprises a skeleton and a curable mixture, the upper side of the skeleton is connected to the surface layer matrix, and the lower side is connected to the bottom layer matrix, and the curable mixture is filled between the surface layer matrix and the bottom layer matrix; the curable mixture comprises cement (4) and reinforcing fibers (5); It also includes an upper connecting bar (14) and a lower connecting bar (15), the upper connecting bar (14) and the lower connecting bar (15) being respectively arranged on opposite sides of the edge of the cement blanket; an upper curing groove (16) with an opening facing downward is arranged on the lower side of the upper connecting bar (14), and a lower curing groove (17) with an opening facing upward is arranged on the upper side of the lower connecting bar (15), and both the upper curing groove (16) and the lower curing groove (17) are filled with the curable mixture; The upper curing tank (16) is provided with a first water-soluble film (18) at the position of the notch for sealing the notch of the upper curing tank (16), and the lower curing tank (17) is provided with a second water-soluble film (19) at the position of the notch for sealing the notch of the lower curing tank (17).

2. The high-strength and ultra-fast curing cement blanket according to claim 1, characterized in that: The skeleton includes a column line (3), a surface layer matrix includes an upper woven mesh (1) and an anti-slip belt (12), and the bottom layer matrix includes a mesh layer (8) and a lower packaging layer (2). The column line (3) is reciprocatingly woven with the upper woven mesh (1) and the mesh layer (8), and a plurality of columns (7) are formed between the upper woven mesh (1) and the mesh layer (8) so that a gap is left between the upper woven mesh (1) and the mesh layer (8); the anti-slip belt (12) is arranged on the upper side of the upper woven mesh (1); and the lower packaging layer (2) is connected to the lower side of the mesh layer by bonding.

3. The high-strength and ultra-fast curing cement blanket according to claim 2, characterized in that: The material of the upper woven mesh (1) is one of carbon fiber, basalt fiber, ultra-high molecular weight polyethylene, steel fiber, steel wire, polyester, and nylon; the material of the column line (3) is one of carbon fiber, basalt fiber, ultra-high molecular weight polyethylene, steel fiber, steel wire, polyester, and nylon; the material of the lower packaging layer (2) is one of carbon fiber, basalt fiber, ultra-high molecular weight polyethylene, steel fiber, and steel wire.

4. The high-strength and ultra-fast curing cement blanket according to claim 1, characterized in that: The reinforcing fibers (5) are steel fibers, and both ends of the steel fibers are bent to form end hooks (10).

5. The high-strength and ultra-fast curing cement blanket according to claim 1, characterized in that: The cement (4) is magnesium phosphate cement.

6. The high-strength and ultra-fast curing cement blanket according to claim 2, characterized in that: The lower side of the lower packaging layer (2) is further provided with reinforcing ribs (13), and the reinforcing ribs (13) are provided along the width direction of the lower packaging layer (2); a plurality of reinforcing ribs (13) are provided, and the spacing between two adjacent reinforcing ribs (13) is set to 1-2m; the anti-slip belt is a diamond abrasive anti-slip belt.

7. The high-strength and ultra-fast curing cement blanket according to claim 1, characterized in that: A first honeycomb plate for dividing the upper curing tank (16) into a plurality of honeycomb holes is provided in the upper curing tank (16); and a second honeycomb plate (20) for dividing the lower curing tank (17) into a plurality of honeycomb holes is provided in the lower curing tank (17).

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